Plasma Cutting Versus Laser Cutting

Laser and plasma cutting systems are two types of metal cutting processes that are widely used in industrial manufacturing applications. Some other processes used in cutting metals include mechanical and thermal machining, welding, electrochemical, flame cutting, abrasive jet cutting and electro discharge machining. As compared to many of these processes, laser and plasma cutting systems are considered faster and more efficient.

Plasma Cutting Process

Plasma or plasma arc cutting (PAC) process, was developed in 1950. The process was especially developed for cutting stainless steel, aluminum and copper that can not be easily cut by other processes like flame cutting. The process uses gases like argon, hydrogen, nitrogen, air and oxygen that can conduct electricity and hence have the ability to transmit energy from an electrical power source. The system involves the use of a source of electrical energy, an arc starting circuit and a plasma cutting torch. The torch is connected to the power source and the circuit through leads and cables. The electrically conductive gases transmit energy from the source of electrical power through the plasma cutting torch, which is used for cutting the material.

Laser Cutting Process

Laser cutting technology uses laser beams to cut materials and is used in many industrial applications like cutting, drilling, engraving, welding, ablation and structuring. The material on which the high powered laser is applied, usually burns, melts or vaporizes. In gas lasers, carbon dioxide along with other gases like helium and nitrogen, are used as a medium. On the other hand, neodymium ions and Yttrium-aluminum-garnet (YAG) crystals are used in solid-state lasers.

Plasma Cutting Versus Laser Cutting

While choosing between plasma and laser cutting, an appropriate evaluation of both the processes is required. The laser cutting process is known for its precision and accuracy. It is very efficient in cutting metal and metal surfaces with accurate precision and causes only negligible surface cracking. The process is also faster and can cut all metals except reflective metals like aluminum and copper, which can reflect a major portion of the laser energy. Other than metals, it is also suitable for cutting plastics, glass and wood. But laser cutting requires more energy and hence is more expensive than plasma cutting. Besides, it can't cut materials thicker than 0.5 inches.

Plasma cutting, on the other hand can cut any metal up to 6.0 inch thickness. It is less expensive than laser cutting and can also be used for cutting aluminum and copper that can't be cut by the laser cutting process. But it affects a large area surrounding the cut, while laser cutting affects a very narrow zone. Plasma cutting can lead to the formation of dross or re-solidified metal, at the lower edge of the cut. Laser cutting can not easily cut materials with different melting points, while plasma cutting can be effectively used for the same. As far as the safety considerations are concerned, laser cutting can be termed safer, as the workers do not come in contact with the machine. Therefore, safety glasses may not be required, however, it is advisable to wear them. On the other hand, in plasma cutting, protective safety glasses are a must.

So, both the processes have certain advantages and disadvantages as well. A proper assessment and research about these processes are required before opting for any particular process. Besides this, some other important determinants are the amount of investment, operating cost and individual requirement of a particular type of industry. Therefore, before making a concrete decision, a professional in this field should be consulted.